Connects the 12 V battery to the power distribution and charging systems.
Concentrically twisted tinned copper with Tefzel insulation (M22759/18 and /32, 8-22 AWG by sustained current), covered in Raychem DR-25 heat shrink, terminated in Deutsch DTM connectors at sensors and DT connectors at high-current items.
No part-specific design process is documented. The Electrical Harness subsystem design process applies: 1. Collect the sensor list and the datalogger assignment for each sensor. 2. Draw the harness in RapidHarness: main connectors, sensor connectors, connections, then bundles and split points. 3. Order wire early. BMRSWired lead time has run 2 weeks to 3 months and is the single highest-impact long lead item. 4. Cut and crimp terminals, assemble connectors, build service loops. 5. Twist the harness, cover with DR-25 heat shrink, test fit on the frame, then install and recover transition boots and connector boots.
Designed in RapidHarness, then cut, crimped, assembled with service loops, twisted, covered in DR-25 and test fitted on the frame before boots are installed.
8 AWG throughout the charging system.
CR22 Issue Log, 2023-12-03: all three batteries died during a drive day because the stator-to-rectifier crimps had failed, so the car was never charging. Fixed by re-splicing the three phase wire to the connector.
Nothing in CrimsonStorage covers these yet.